LINCOLN HELIOS (INDIA) LIMITED

CUSTOMER : M/S. Humboldt Wedag (I) P. Ltd.

EQUIPMENT : SLIDE SHOE LUBRICATION SYSTEM

PROJECT : KCP Cement

LHIL SO NO. : 1002450

ORDER REF. : 45003243 Dtd. 28.05.2009

Contact Address:

LINCOLN HELIOS ( INDIA) LTD

BG-III,
Devanahalli Road, Off Old Madras Road
BANGALORE - 560 049 INDIA

PH.NO. : 080 28472424/425/621/28473008/28473104

FAX NO.: 080 28472566
E-MAIL : mktg@lincolnindia.com
URL : www.lincolnindia.com

This manual is subject to change without notice

 CONTENTS
1.0 INTRODUCTION

2.0 CONSTRUCTION AND OPERATION OF SYSTEM

3.0 MAINTENANCE & TROUBLE SHOOTING

4.0 INSTALLATION

5.0 MAINTENANCE & TROUBLE SHOOTING

6.0 LIST OF MAINTENANCE SPARES

7.0 CATALOGUES

8.0 DRAWINGS
SECTION 1.0
1.0 INTRODUCTION
1.0 INTRODUCTION
The instructional manual is concerned the situations which, according to our
experience, are the most likely to occur. An exhaustive enumeration of all
conceivable situations which may occur during the operation of the system cannot be
provided.

Consequently, if a situation should arise, the occurrence of which is not foreseen in

the instruction manual and which client is / or feels unable to handle, we would
recommend to consult LINCOLN HELIOS INDIA LIMITED without undue delay for
advice on appropriate action.

Address of the servicing Department.

LINCOLN HELIOS ( INDIA) LTD

BG-III,
Devanahalli Road, Off Old Madras Road
BANGALORE - 560 049 INDIA

PH.NO. : 080 30710000

FAX NO. : 080 30710001
E-MAIL : mktg@lincolnindia.com
URL : www.lincolnindia.com
 SECTION 2.0
2.1 CONTRUCTION AND FUNCTIONAL
DESCRIPTION
2.2 ELECTRICAL WRITE UP
2.2 REFERENCE DRAWINGS /DOCUMENTS
2.1 CONSTRUCTION AND OPERATING DESCRIPTION

The Slide shoe Lubrication System consists of two systems for each mill;
1. HP-LP (High Pressure - Low Pressure) Lubrication system for Loose side of Slide
Shoe Bearing.
2. HP-LP (High Pressure - Low Pressure) Lubrication system for Fixed side of Slide
Shoe Bearing.

High pressure(HP) line consists of a High pressure pump (HP Pump) with Two outlets
& each outlet consists of a non return valve safety valve, pressure gauge and pressure
Switch in the delivery line.

The High-pressure (HP) Pump is a radial Piston pump with a rated capacity of 5LPM
@1500 rpm and maximum working pressure of 400 bar. The high pressure pump
delivers the starting oil pressure required for pre-jacking of the mill bearing.

Low pressure (LP) line consists of two Low pressure pump (LP Pump) with Check
valves, Oil cooler, Pressure gauge, Temperature gauge,RTD, Globe Valves ,and Oil
flow switch in the delivery line.

The Low Pressure pump is a GEAR PUMP with a capacity of 150 LPM @1500 rpm and
the LP system is rated for 16 bar maximum working pressure . The low-pressure pump
is responsible for oil circulation required during the mill running condition.

The system shall be switched on once all the electrical and mechanical connections
are made as per the following drawings:

Schematic drawings : 1002450-1000 & 1002450-2000 – 1st Mill &

1002450-1000A & 1002450-2000A- 2nd Mill
Pump station Assembly drawings : 1002450-1001

SYSTEM OPERATION

1) There is one HP Pumps used for pre-jacking purpose & there are two LP Pumps
used for oil lubrication/circulation out of which one will be pumping the oil
continuously & other acts as stand by.Before starting the system ensure the oil
temp. to be 40 deg.c inside the tank for which the 2 nos. Heater s are provided .

2) RTD has been provided to monitor the oil temperature in the Tank .
The Signal from the RTD is used to switch on or Off the Heater in the Tank .
3) 3 Nos. Level switches are provided which provides electrical signal to Dcs &
indicates the High ,Low & Low- Low levels in the system.

4) Initially the HP pump will be switched on for Prejacking and after the receipt of
the limit switch signal from the mill the Lp pump is switched on.The Hp pump
has Two outlets. The two outlets are connected to the Line 1 & Line 2 of the
sliding Block.

5) Each outlet of HP Pump is provided with a Pressure Switch which continuously

gives the feedback of the healthiness of the system.

6) Two LP Pumps are provided in the system, one working and one acts as
stand by. At the outlets of each pump NRV is provided.

7) Heat Exchanger is provided in the LP line to maintain the Oil Temperature at

43 Degree C.Also an additional Heat exchanger is provided in the Low pressure
Oil sprayer line to maintain the temperature at 40 Deg.C

8) A Temperature Sensor RTD is provided at the Heat Exchanger outlet, which will
monitor the temperature of the oil going to bearing continuously. RTD will give
the feedback in ohms to DCS panel.

9) Also a Temperature Gauge and Pressure Gauge is provided for visual

monitoring of Oil temperature and pressure in the system.

10) The outlet of the system is branched into five outlets in Fixed End & Three
outlets in Floating end system & Each outlet is provided with a Needle Valve &
Flow Switch. Needle Valve is used to control the flow going to the equipment.
Flow switches continuously monitors the flow at each outlet. Flow Switch gives
the signal to the DCS panel in case of drop in the flow.

11) An online Emptying / filtering Pump in tank is provided which can also be
used as a filling pump unit. At the outlet of Emptying pump a Duplex Filter is
provided to filter the oil while filling oil to tank.

12) A Differential Pressure Switch is provided across the Filter to indicate the clogging
signal to the DCS Panel.
GENERAL SPECIFICATIONS :

Parameter Oil Circulation Filtering Pre-Jacking

System System System
[Low pressure(LP) [Axial. Supply [High pressure(HP)
line] (AX) line] line]
Working pressure 16 Bar Max. 5 Bar Max. 400 Bar Max.

Working temperature 400C (+/-5%) 700C (+/-5%) 700C (+/-5%)

Flow rate 150 LPM @1500 150 LPM 5+5 LPM @1500
RPM @1500 RPM RPM
(Free flow) (Free flow) (Free flow)

Filtration Grade - 60µ -

Heat exchanger capacity

- -
Oil In/Out temperature 700 C(+/-5%)/430 C
Water In/Out temp. 380C/420C
Max.working pr.Oil/Water side 12 /3 Bar Max.
Cooling Water requirement 380LPM

• Fluid medium / viscosity Lub. Oil SO VG 460 Lub. Oil SO Lub. Oil SO VG
grade @400 C or VG 460 @400 C 460 @400 C or
Equivalent or Equivalent Equivalent
• Electric source supplied 415V-50HZ-3Ph AC 415V-50HZ- 415V-50HZ-3Ph
for motors 3Ph AC AC

• Control voltage 110V-50HZ-1Ph AC 110V-50HZ- 110V-50HZ-1Ph

24 Vdc for AC AC
Transmitter

2.2 ELECTRICAL WRITE-UP

The SLIDE SHOE BEARING LUBRICATION system consists of:
- Pre-jacking system (also referred as HP system)
- Oil Circulation System (also referred as LP system) and both the systems are
mounted on the common Oil reservoir.
- Emptying / Filtering Pump system
- One set of system auxiliaries.
1. High-pressure system
The HP system consists of pump (HP pump) having the following electrical accessories
a. Pump motor.
b. Pressure switch .

2. Low-pressure system
The LP system consists of one Low-pressure pumps (LP pump). Each LP line consists of
the following electrical accessories
a. Pump Motor
b. Oil Flow Switches
c. Pressure Transmitter
d. RTD
e. Air Solenoid valve to Butterfly valve actuator in oil sprayer line

3. Filtering System
a. Pump Motor
b. Differential Pr. Switch

4. System auxiliaries (Other than the ones mentioned above)

a. Electrical heater
b. RTD
c. Level switch

Voltage:
All the system auxiliaries are rated for 230V AC power supply except for Pr.
Transmitter which is rated for 24 VDC. The Incoming Voltage of 415V, 50 Hz, 3 Ph, AC
shall be provided by the Customer’s MCC to drive the motors. The Control Voltage of
230 V AC shall be provided by the customer’s MCC to drive the Customer PLC.

System Protection
The customer shall provide the necessary protective devices like Over Load Relay and
MCBs for protecting the Motors against faults like Over-load and Short circuit.
Customer shall provide proper Indicating and annunciating mechanisms at suitably
wherever it is required to indicate/announce the status of the system critical faults.

Features:
Main Switch to be provided to isolate the Control Panel from the incoming supply. The
Control Panel is equipped with the necessary protective devices like Over Load Relay
and MCB for protecting the Motors against faults like Over-load and Short circuit.
Pilot lamps and hooter should be provided in the Control Panel to indicate the status
of the system and announce the critical faults. Hooter can be accepted by using
hooter accept Pushbutton.

System working:
System can be made to operate in either Local or Remote mode by selecting through
Selector switch.

Local mode:
In Local mode the system can be started / stopped using Push buttons respectively.

Remote mode:
In Remote mode the ON / OFF command has to come from customer’s PLC .

Initial Condition:
System has to be switched ON in either Local or Remote mode.

Each of the two LP Lines and the HP line has a selector switch to operate the system
in ‘Auto’ mode or ‘Manual’ mode.

Fault Monitoring:
The system is protected against faults like low pressure, filter clogging, low flow and
high oil temperature etc.

Low Pressure Transmitter:

Low-pressure transmitter provided in the HP line,LP line & auxillary line continuously
monitor the pressure . The output of the transmitter is given to customer PLC. In
case the system does not build up the required pressure within the pre-set time the
signal can be used for Audio /Visual indication .
Flow Switch:
Each of the LP lines has got a flow switch, which is set as per drawing of the system
flow rate. The flow switches are monitored using On-delay timers. If the system does
not build up the set flow rate within the pre-set time of the On-delay timers, the
timers change over their contacts after counting the pre-set time and give an audio
and visual fault indication by energizing the hooter and pilot lamps.

Differential Pressure Switch:

The differential pressure switches provided in the Emptying / Filtering lines monitor
filter clogging. When the differential pressure across the filter reaches the set value
in the differential pressure switch, indicating filter clogging, the differential pressure
switches change over its contacts to give an audio and visual fault indication by
energizing the hooter and pilot lamps.

Pilot lamps are provided to indicate the status of the system. Potential free contacts
are provided for feedback to customer’s MCC / PLC.
The following Push buttons to be provided:
1. Emergency stop.
2. System Stop and System Start.
3. HP system Stop and Start.
4. LP System Stop and Start.
5. Empty Pump Stop and Start.
6. Fault Reset.
7. Hooter Accept.
2.3 REFERENCE DRAWINGS/ DOCUMENTS
Reference drawings :
Sl.no. Description Drawing no.

1 Schematic drawing of HP-LP Lubrication system for Loose 1002450-2000

side of Slide Shoe Bearing Mill-1

2 Schematic drawing of HP-LP Lubrication system for Fixed 10002450-1000

side of Slide Shoe Bearing Mill-1

3 Pump station assembly for oil circulation and pre-jacking 1002450-1001

system for Fixed & Floating side of Slide Shoe Bearing

4 Schematic drawing of HP-LP Lubrication system for Loose 1002450-2000A

side of Slide Shoe Bearing Mill-2

5 Schematic drawing of HP-LP Lubrication system for Fixed 10002450-1000A

side of Slide Shoe Bearing Mill–2

Catalogues: Pumps, Motors, valves, Gauges, Heat exchanger, Filters, Switches etc.
SECTION 3.0
3.1 INSTALLATION
3.1 INSTALLATION

• The pump stations ares to be fixed by means of expansion bolts.

• While installing the pump station, the frame must not be subjected to any
mechanical stresses.

• Sufficient volume of oil in the tank shall be made available all the time for smooth
running of pump without noise/cavitation and turbulence during system operation
to achieve gravity suction.

• Connect the Oil cooler water connections.

• Make oil piping as per the schematic diagram.

• See separate instructions for hydraulic installations instructions and assembly of

pipes.

• The pipelines shall not be subjected to any mechanical forces and must be
supported in a manner ensuring that leaks in the pipe joints cannot occur as a
result of vibrations.

• Provide clamps for every 1.2 mtr length of pipe.

• The suction line must be installed with a slope from the bearing towards the pump
station.

• Check the voltage and frequency of the electric motors.

• Check the rotational direction as indicated by the arrow on the pumps.

• Complete electrical connections of motors, pressure Transmitters and flow switch.

 SECTION 4.0
4.1 INITIAL START UP
4.2 OPERATION
4.1 INITIAL START UP

a) Check oil level in the mill bearing.

b) Open the ball valve in the Suction line/Return line.

c) Open the ball valves / Open the needle valve in the delivery line of the LP (Low
pressure) Pump, HP (High pressure), and the isolatation valve of filter by turning
the 3- way ball valve at the in the filter).

d) Vent the pipe line and check the oil flow freely to the pump station. Close the
vent screw again and check that it is tight.

e) Check all electrical connections as per the schematic drawing.

f) Operate the system in manual mode(Control panel is not in LHIL’s Scope) in

manual mode.

g) Start up the LP Pump and check that the oil in the mill bearing is flooded.

h) Check that the oil level indicator in the bearings (not in LHIL’s scope) functions
properly. If it is provided in the system, it must give alarm as soon as the oil flow
to the oil distributor is interrupted.

i) Check for oil leakage. The Oil flow switch provided in the pump station is to set for
low flow. The signal from the Flow switch is to be used for giving an alarm /
indication from the Control panel as soon as the oil flow in the flow line falls
below the set flow rate.

j) Check for the oil blockage. The rise in pressure due to the blockage is indicated by
the pressure gauge provided in the pump station.

k) Start up the HP (high pressure) pump. Open the pressure gauge needle valve and
check the pump pressure on pressure gauge. The maximum pressure of the pump is
160 bar ( i.e., relief valve set pressure). The pressure may very from 0 to
maximum level depending on the back pressure.

l) Check that all pipes joints for tightness.

m) Ensure that ball valve in the suction line / return line is not closed during system
operation.
n) Pressure Transmitters are provided in the LP Lines for monitoring the system
pressure.

o) Ensure the availability of the cooling water for Cooler. Temperature gauge
provided at the outlet of the cooler for monitoring of the temperature of the oil.

o) The system is now ready for operation.

p) Turn the control panel to auto mode.

Caution : Pump should not run dry.

4.2 OPERATION

During the start up and operation, the pump station is controlled automatically from
Customer Control panel.

High pressure (HP) pump as well as the Low pressure ( LP) pump must be running
before the mill can be started.

High pressure pump will normally be stopped as soon as the mill starts operating.

LP pump must always be running while mill is in operation.

 SECTION 5.0
5.0 Introduction
5.1 Inspection
5.2 Servicing
5.3 Repair
5.4 Routine
Maintenance
5.5 Trouble shooting
5.0 INTRODUCTION
In general the term "Maintenance" can be broken down into the following three
activities:

5.1. INSPECTION

Action taken to maintain the status quo i.e., ensuring that wear margins and reserves
are used up at as slow a rate as possible during the service life of the equipment.

5.2 SERVICING

Action to ascertain the actual status quo i.e., determining how and why wear margins
& reserves are being used up.

5.3 REPAIR

Action taken to restore the status quo i.e., to re-establish wear margins and reserves
and restore loss of performance.

With oil lubrication installations the term "loss of wear margins and reserves" means :
• increased clearance between spools & bores
• worm dynamic sealing elements
• fatigue of rolling bearing materials
• excessive clearance between plain bearings and shafts
• cavitation damage to pumps and valves
• chemical changes to fluid

Each one of these "forms of wear" slowly uses up the reserves provided at design stage
until the point is reached where either a component fails abruptly or prescribed
reference valves can not be attained. The latter is not always identical to the failure
of a piece of equipment.

5.1.0 MAINTAINING OIL LUBRICATION INSTALLATIONS:

The enormous variety of applications for oil lubrication means that the type of
equipment encountered ranges widely from the simplest unit incorporating perhaps
one pump supplying one actuator to major complex installations incorporating several
pumps and highly sophisticated bearings.
The maintenance needed by these installations must be planned and executed
according to such factors as the required availability, the value of these installation,
its usage (intermittent or multi-shift continuous) and the consequences of a break
down (an individual unit performing some subsidary task or an important sub-system
which would result in the shutdown of a whole line should it fail).

The individual point of a particular installation requiring inspection should be put

down "inspection lists" so that it is possible for them to be attended to with adequate
thoroughness by persons of different level of skill. (Refer Maintenance Chart)

In the case of large installation there will be different inspection points according to
different periods of service e.g. daily inspection points, monthly inspection points and
inspections shortly before an extended shutdown e.g. holidays.

The principal inspection points are as follows :

5.1.1CHECK TANK/RESERVOIR FLUID LEVEL

A low fluid level is usually indicative of a loss of fluid through external leaks.
After major repair work the fluid level can sometimes continue falling slowly
for sometime as the system automatically bleed itself of air.

A high fluid level can be indicative of parts of the system at a higher level
draining while shut down due to the ingress of air. Water can gain access to the
oil system through leaks in water/ fluid heat exchangers.

5.1.2 CHECK OPERATION OF HEAT EXCHANGERS

Water/ Oil type :

The Water circulating through the heat exchanger must be clean so that no
insulation deposits of sludge can interfere with the transfer of heat. This is
particularly important if the flow of water is regulated in order to maintain a
constant fluid temperature and so there is no high water velocity to flush away
any sludge that might build up. It is important for neither the water side nor
 the fluid side of water type heat exchangers to be allowed to drain otherwise
only part of the surface area will be utilized for heat transfer. (Refer catalogue
for details)

5.1.4 CHECK FOR EXTERNAL LEAKS (VISUAL EXAMINATION)

Examine all rigid pipes, flexible hoses (particularly the connectors), pumps
valves and actuators.

5.1.5 CHECK FLUID SERVICE TEMPERATURE

A rise in fluid temperature can be due to a number of causes :

An inefficient heat exchanger (dirty surface, broken fan, insufficient circulating

water, high circulating water temperature, sludge build-up in heat exchanger
etc)

Heat generated in pumps or motors due to damage to either rolling bearing or

plain bearings.

Heat radiation from the tank, the piping and the components reduced by a
build-up of dirt.

Increased internal leakage in individual components, pressure relief valves

lifting at too low pressure, failure of load sensing control, system being
operated outside the permitted limits etc.

5.1.6 CHECK PRESSURE SETTINGS

Check the operating pressures of pressure relief valves.

5.1.7 CHECK LEAKAGES RATES

With valves and some hydraulic pumps it is possible to assess the internal wear
by measuring the leakage fluid rate. This also applies to a number of control
valves and check valves. The slow extension or retraction of a cylinder under
external load with its isolating devices closed can be indicative of defective
piston seals.
5.1.8 CHECK THE FLUID PURITY
A visual examination will only provide a rough estimate of the condition of the
fluid i.e. cloudness, darker appearance than when new sediment in the fluid
tank.

There are three methods of measuring the purity accurately :

• Gravimetric determination of solids by the filtering of a certain quantity of

fluid (e.g. 100 NW) and weighing of the filter paper before and after filtration.
This will give a figure of solids content in mg/l. However, the actual solids
content will be somewhat higher than the figure recorded because even very
fine filter papers have an average pore size of about 0.8 m.

Although very fine contamination of this size will not actually cause any wear
at normal mechanical fits, it can contribute to erosion in places where the fluid
velocity is very high (e.g. in pressure relief valves, pressure reducing valves,
grooves in control valves etc.).

The gravimetric method also says nothing about the composition of the solids
nor anything about the size distribution. Gravimetric analysis can only be
performed in laboratory or in a laboratory van specially equipped for fluid
analysis.

• Particle counting by electronic counting and sorting devices. Such devices can
function completely automatically. However fluids containing water, mixtures
of fluids and fluids with an excessive solids content cannot be analysed by
these devices. As they are very costly, they are normally only found in the
laboratories of large companies, filter manufacturers & fluid suppliers. With
suitable calibration, the results can be directly compared with the
contamination classes of MAS 1638 or SAE standards.

• Microscopic analysis :
In this case a few precisely - measured drops of fluid are placed on highly
absorbent surface such as a filter paper and the solids remaining on the surface
after the fluid has been absorbed are counted under the microscope. This
method also allows an assessment of the size of the particle distribution and
rough estimate of composition e.g. metal particles, seals residue, silicate,
 fibbers etc. It is a method that allows a quick analysis to be made on site,
where the other methods described can only be performed in the laboratory or
in special equipped vans.

5.1.9 CHECK FOR FILTER CLOGGING

A visual check of the type of filter elements in wide spread use today will
reveal noting.
The amount of clogging can only be determined by measuring the pressure drop
across the filter element (or by measuring the pressure head before the
element with return line filters if there is no fluid resistance left on the clean
side). So that such checks can be performed without the need for instruments,
the filters used in the system should always incorporate a visual clogging
indicator of logging. Solids in the fluid are the main cause of wear in hydraulic
components.

The amount of solids smaller than the pore size of the filters used in the system
is also significant factor because they provide erosion and through a kind of
lapping, increase spool clearances, wear away control surfaces and ruin
dynamic sealing elements. Sudden equipment failure is a rare occurrence but
the actual service life of the component is reduced to a fraction of the design
valve.

5.1.10 CHECK THE CHEMICAL PROPERTIES OF FLUID

It is inevitable that the chemical stability of fluid will be effected to some

extent in time by the severe stress placed upon it by such things as pressure
fluctuations, high velocities, high shear loads, localized, overheating,
absorption of oxygen from the air, contact with various metals, elastomers and
plastics and the absorption of condensation and solid particles.

Consequently, regular tests should be made on the neutralization number,

saponification number (soaping number), oxidation product content, viscosity
and viscosity index.

The tests are more important for mineral oil fluids and so should be performed
more frequently because it is constantly being proved that major damage can
be caused by chemical changes which take place very rapidly although
 outwardly everything appears satisfactory and in order.

If the operator of the system does not have his own laboratory an agreement
can usually be made with the fluid supplier to perform the tests on regular
basis.

When there is only a relatively small amount of fluid involved it is probably

cheaper and simpler to change the fluid periodically in order to avoid the on-
going expense of chemical tests.

5.1.11 CHECKING BEARING TEMPERATURE

When the first pitting appears in the races of rolling contact bearings, the extra
power causes a small rise in temperature in the vicinity of the bearing.
However in order to detect such a change it is essential to have a reference
value which must have been taken at precisely the same point during a specific
work cycle and after the bearing has been run in.

5.1.12 CHECK FOR NOISES

In this case too the object is to detect changes from the status quo when the
equipment was new.

Pressure relief valves normally make a hissing noise when they lift. Therefore if
there is any chattering or whistling it is a safe but that there are some
damaged pressure relief valves or pressure reducing valves in the system.

An increase in hydraulic pump or motor noise with increasing pressure can be

indicative of erosion or cavitation damage to control surfaces, excessive
clearance in displacement elements or incipient bearing damage. Unpleasantly
loud noise from pumps regardless of the pressure but gaining greatly in
intensity as the speed rises are a signal for insufficient boost pressure or
excessive negative pressure in the suction time.
5.1.13 CHECK PIPES AND HOSES

Examine all pipes, connectors and fitting for leaks and ensure that the pipes
are firmly supported everywhere loose pipes can eventually chafe through and
fitting can overstrained.

Kinks and crush points increase the flow resistance causing loss of power and
overheating. Flexible hoses should be examined for chafing and bulges and
their correct installation should be double checked all the hose fittings should
be inspected for leaks.

In actual practice the division between inspection servicing and repair are not
so strict as definitions would suggest. It is common, for example, for servicing
to be carried out at the same time as inspection.

5.2.0 SERVICING
The main servicing work involves :
5.2.1 TOPPING UP THE FLUID

The fluid with which the system is topped up should always be the same as that
already in the system. This is a particularly important point to note in the case
of mineral-oil-fluids from different manufactures because they may differ in
base oil and additives.

In the case of HFA, HFC and HFD fluids it is very important not to mix different
makes of fluid. Even when fluids of same type, but from different suppliers, are
mixed there is possibility of liability for any damage being refused.

Numerous additives for hydraulic fluids are now on the market which are
supposed to reduce mechanical friction, eliminate the slick-slip effect almost
entirely extend the life of the fluid and perform many other useful functions.

Before contemplating the use of such additives it is absolutely essential to

obtain the approval of the fluid supply in order to be certain that the two are
compatible. However, it must be said that hydraulic fluid suppliers very often
refuse all liability if additives not of their own make are mixed with their
 hydraulic fluid. Hydraulic equipment manufacturers adopt a similar attitude
because it is enormously costly and time consuming to ascertain the long-term
effects and true compatibility when there are fluctuations in the mix ratios and
applications vary widely.

5.2.2 CHANGING THE FLUID

Hydraulic fluid should be replaced as soon as any changes in its chemical

properties start to take place, e.g. the presence of oxidation products,
increase in neutralization number of saponification number, disappearance of
essential additives, change in viscosity, etc.

The fluid should also be changed when the fine contamination (i.e. the content
of solids smaller than the pore size of the system filters) has increased to a
point where greater long-term wear must be anticipated (e.g. over 250,000
particles between 5 and 15 mm per 100 ml). Expensive purification processes
such as centrifuging (if the type of fluid will allow) or filter presses are only
economical if the quantity of fluid is large. Since the amount of fluid in the
actual system, i.e. pumps, pipes, control gear and cylinders, is sometimes
several times more than the capacity of the tank it is not enough to change just
the amount of fluid in the tank. This is especially true if the old fluids is
already showing signs of chemical instability.

The oil tank /Reservoir must be cleaned out every time the fluid is changed.

An important point to remember, both when topping up and changing the

whole quantity of fluid, is that new fluid as-supplied is not normally
immediately suitable for use in a hydraulic system due to the quantity of solids
which it contains. The chain of supply from manufacturer to end-user is often
very long, passing through storage tanks, sea and road-going tankers, tank cars
and various types of container, and the required purity cannot be guaranteed.

Therefore, for topping-up and for complete renewal the new fluid must be
passed through a suitable filter first. Its pore size must be at least equal to that
of the filters fitted in the system but it is better for it to be smaller.
 This is a very important point requiring close attention otherwise there is a
possibility of malfunctions immediately after the fluid has been changed.

5.2.3 CLEANING THE FILTERS

Filter elements should also be cleaned or changed every time the fluid is
changed.

With the types of filter fabrics in widespread use today cleaning is not a
practical proposition so the elements are changed. The amount of clogging of a
filter element can only be discovered from the pressure drop across it since
nothing can be seen with the naked eye. Without artificial aid, the human eye
is only able to see particles larger than about 45 to 50 mm in size. This means
that all filters used now should be the type incorporating a visual or electric
clogging indicator showing when maximum clogging has been reached. Filters
without such a monitoring device must be changed at regular intervals which
should be short enough to ensure that the by-pass valve does not lift or the
clogged element burst.

5.2.4 READJUSTING PRESSURES

Readjust all pressure settings - pressure relief valves in the working circuit,
control circuit and low-pressure circuit.

5.2.5 DEALING WITH LEAKS IN THE PIPEWORK

Resealing work on the pipework should only be performed with the system
depressurized. Leaks from fittings incorporating soft seals such as O-rings
cannot be eliminated by re-tightening because the seals will either have broken
or gone hard. A new seal will have to be fitted in order to effect an
improvement.

5.2.6 CLEANING THE INSTALLATION

The exterior of a hydraulic installation should be cleaned occasionally so that it
is easier to find leaks, so that no dirt is carried in when topping up the fluid or
changing filter elements, to protect cylinder rods from being scored as so as
not to interfere with the amount of heat
 When cleaning an installation, however, it is important not to allow any cleaning
liquids to gain access to the hydraulic system.

If high-pressure steam cleaning equipment is used, care must be taken that

tank covers, pipe glands, shaft seals, electrical equipment, etc. are able to
withstand it.

5.2.7 REPLACING WORN COMPONENTS

The circumstances of hydraulic component failure are very difficult to predict.

The conditions of the particular application are a very important factor, e.g.
dynamic pressure stresses, flow velocities, type of fluid, thermal stresses,
environmental factors. etc.

For known applications it is possible to predict approximate average service life

figures for rolling-contact bearings and dynamically loaded seals. Precautionary
renewal of rolling bearings, cylinder seals, dirt wipers, hoses, etc. can be
sensible if the total failure of such items can have serious consequences.
For example, this applies if :
1) Damage to a rolling bearing can cause the total destruction of a whole drive
system
2) Uncontrollable cylinders can result in collisions with other parts of machines
3) Burst hoses can cause major environmental pollution or danger to life and
limb

The precautionary renewal of wearing parts during servicing is also a good idea if the
system is employed on multi-shift working and is integrated into a production line
which would suffer a total shutdown should the system suffer a malfunction.

- All elastomer and polyurethane based sealing elements exposed to static and
- dynamic loads
- Inserts of pressure relief valves, pressure reducing valves, pressure sequence
valves and unloading valves
- Solenoids, when very high switching frequencies are involved
- Filter elements, if there is no monitoring of clogging
- Inserts in flexible shaft couplings
- High-pressure hoses, if conditions cause the manufacturer to guarantee only a
limited number of stress reversals

5.3.0 REPAIR

5.3.1 FAULT-FINDING
Any repair to a system must be preceded by successful fault-finding.

It requires a systematic approach, one of the basic necessities for which is the
easy availability of all the relevant documentation.

It is desirable for a circuit diagram containing lists of components and a

function sequence chart to be kept constantly available close to the
installation.

Past experience has shown that it is an excellent idea to paste the diagrams on
to boards and then either varnish them or cover them with Perspex to prevent
them becoming dirty or damaged. Good illumination is also beneficial.

Important measuring instruments should also be available close by, especially

on the larger installations. The most important fault-finding tools for a
troubleshooter are pressure gauges of the necessary measuring ranges. In order
to maintain accuracy and an acceptable service life, pressure gauges should
normally be chosen so that only 2/3 to 3/4 of the maximum scale reading is
utilized. Pressure gauges can be connected quickly and without loss of fluid
through Minimess quick-release connectors and hoses of 1.8 to 2.4 mm bore. It
is important to re-seal the connecting points afterwards with the screw caps to
keep out dirt and to protect the sealing surface.

STANDARD TOOLS
THERMOMETERS:
(Electronic thermometers with surface sensors are best)
- For quickly finding points of high temperature due to leaks, power loss, etc.

MULTIMETER:

- For checking the resistance of solenoids

- For measuring the voltage at solenoids (the voltage is not measured at the
coil terminals in the switchgear cubicle).
- For measuring the current at proportional valves and servo valves.
 Naturally, there are also many other specialized measuring instruments
available on the market for measuring voltage and current which have been
specifically designed to be very easy to use.

INDUSTRIAL STETHOSCOPE
- For pin-pointing noise sources through structure-borne sound
STOPWATCH:

- For measuring extension times and retraction times of cylinders

- For measuring leakage rates from hydraulic pumps and motors

TACHOMETER:

- For measuring the speed of hydraulic motors

MEASURING FLOW RATES:

The electrician has an easy task measuring current compared with the
hydraulic engineer trying to measure flow rate.

The system has to be opened up in order to fit a flow-meter, with the

attendant danger of fluid contamination and fluid loss.

Only few instruments are able to withstand the pressures involved and the
measuring range is often relatively small. Consequently, the hydraulics
engineer usually has to measure flow rate indirectly through the operating
times of cylinders and the speeds of hydraulic motors.

5.3.2 FAULT RECTIFICATION

Generally speaking, fault equipment should not be repaired on site because
neither the necessary tools nor the necessary cleanliness are normally available
there. Whenever possible the procedure should be to change complete items or
sub-assemblies locally.
- so that the system is only opened up for as long as is absolutely necessary
- So that fluid loss is kept to a minimum
- So that the down time is kept to a minimum by using overhauled and pre-tested
equipment

Another very important factor after the failed item of equipment has been pin-
pointed is to ascertain whether the failure has caused any contamination of the
remainder of the system due to broken pieces of metal or large quantities of
metal residue.

If inspection of the filters or tank reveals such contamination, it is absolutely

essential for the whole installation to be cleaned, e.g. by flushing, before it is
returned to service. The filter elements should also be changed and, depending
on the particular type of installation, it might be necessary to change the fluid.

In the case of larger installations the fluid can be cleaned either by filter or
centrifuge.

This is the only way of preventing further malfunctions and the possible failure
of other components due to secondary damage.

As an extra safety factor, particularly with sensitive systems which have to

perform very precise control functions, it is sensible to fit the filters, for a
limited period of time (e.g. until they reach their clogging limit), with
elements of the next smaller pore size. This is nearly always possible with
modern filters. When a system has been returned to service after repair it
should be kept under close observation for some time in order to be certain
that the repair has actually eliminated all the problems. Sometimes there is
some irregular operation for a period if part of the system has not been
properly bled of air, e.g. cylinders "spring" or overrun positions, pumps give off
loud knocking noises, etc. If systems are self-bleeding, this type of irregularity
might last for several hours.
 5.3.3 REPAIR OF HYDRAULIC COMPONENTS

Before the actual repair of any hydraulic components is started, a decision

must be taken on which components can be overhauled by the operator himself
and which can only sensibly be overhauled by the equipment manufacturer.

The repair of hydraulic components needs a suitably equipped workshop in

which the standards of cleanliness are above average compared with a normal
mechanical engineering workshop. Obviously, this is only an economic
proposition if the company involved possesses large amounts of equipment
containing a high proportion of hydraulic systems.

The second need is for properly trained staff and all the relevant
documentation.

However, both of these preconditions are useless and inefficient if there is not
also a comprehensively stocked store of spares available.

What components can be repaired or overhauled by the plant operator for an

economic outlay?

5.3.3.1 CHECK VALVES

Nearly all types of check valve have metallic seats. Often the cone is harder
than the seat in the body.
The main problems with this type of valve (non return valves, prefill valves,
logic elements etc.) are :
- Hardened seats. They can be easily changed. Great care must be taken when
opening up the body because the springs inside are sometimes very strong.
- Internal leakage due to damaged valve seats. Such damage is nearly always
caused by foreign objects or erosion.

A repair can be effected either by re-machining the seat or by changing both

seat and cone.

The re-machining of body seats needs absolute precision since practically no

misalignment between seat and guide is allowed.

A static leakage test is easy to perform.

 5.3.3.2 HYDRAULIC ACCESSORIES

Hydraulic accessories take the form of :

Filters, pressure switches, pressure gauge selectors, oil heat exchangers,

water/oil heat exchangers etc. some of these items are repairable whereas for
others it is not an economic course of action.

5.3.4 REPAIR AND GENERAL OVERHAUL OF HYDRAULIC EQUIPMENT

The bottom line as far as the repair and general overhaul of hydraulic
equipment is concerned is that the equipment manufacturer can do it more
economically and more safely.

This is because:

- The repair departments of equipment manufacturers work to the same quality

standards on general overhauls as for the production of new equipment
- Repair personnel are trained in exactly the same way as personnel who work
on new equipment
- Spare parts are made on the same machines that produce new parts
- Full test facilities are available
- Overhauled equipment is usually subjected to stiffer tests than new
equipment
- Equipment manufacturers guarantee the same performance from overhauled
equipment as for new equipment
- Some equipment manufacturers offer the same guarantee period for
overhauled equipment as for new equipment

5.4. MAINTENANCE
5.4.1 ROUTINE MAINTENANCE
a) Check the level in the bearing sump before starting the system. Add oil if required.
This will ensure the dry running of the pumps.

b) For the fist week after commissioning check the filter every day and clean it if
necessary. This will give some idea about the contaminates in the system that are
getting mixed with oil. After the first week, you can fix up the time interval
between the consequent filter cleaning. Never allow the filter to go unattended
 and get clogged. Clogging indication gives you an indication of the extent of
clogging.
c) The Differential pressure switch can be set for filter clogging pressure, the signal
from the same is used for giving an alarm / indication from the Control panel (not
in LHIL’s scope) as soon as the pressure rise beyond the set pressure difference in
the differential pressure switch.

d) Measure the oil temperature in the suction line , the bearing region (not in LHIL’s
scope) and cooler outlet temperature. Keep the regular log of the same.

e) Check the pipe joints and tighten them up every month if necessary.

f) Pressure of the system must be checked periodically.

g) Ensure cleanliness of the system and its surroundings as dirt is a major

contaminant.

5.4.2 PREVENTIVE MAINTENANCE, SURVEY

1 Lubrication
2 Clean up
3 Inspection and adjustment
4 Checking of the condition
5 Replacement (incl. Lubricants )
Text 1 2 3 4 5

Pump station - - S - -
Suction filter - T S - -
Pressure line filter - S - T
Oil cooler - T - - -
D = Per 8 hours of operation
S = Weekly
M = Monthly
A = Yearly
T = See text in catalogue
5.4.3 LUBRICATION
The bearings are lubricated by the circulating the oil. For oil grade, reference is made
to the operating instructions of the mill or instruction manual for mill bearing.
5.4.4 CLEAN - UP

PUMP STATION
Clean the machine and surroundings.

SUCTION STRAINER
The filter cannot be cleaned while system in operation. When the mill is stopped, the
filter is cleaned. After closing valve in suction line as per the instruction in catalogue.

PRESSURE LINE FILTER

The filter can be cleaned during operation by directing the flow through standby
filter. This is done by opening the inlet and outlet ball valves of standby filter and
then closing the inlet and outlet ball valves of the filter that is to be cleaned.

5.4.5 INSPECTION AND ADJUSTMENT

PUMP STATION
Check that the pressure and temperatures are normal.

Keep the pressure gauge needle valves closed during operation.

Check the pipelines for leaks. Retightining must be carried out if necessary.

Check that oil flows over the edge of the oil trays in the mill bearing.

Check the oil level of the bearing housing.

SUCTION FILTER & PRESSURE LINE FILTER

Inspect the filter indicator for clogging conditions.

Refer to the catalogue to understand clogging condition.

If the filter indicator always shows any signs of clogging, the filter element must be
replaced.
OIL COOLER
The cooler must be cleaned if required. This may be done when mill is not in
operation. Refer catalogue for dismantling , cleaning instructions.
5.5.0 TROUBLE SHOOTING - GENERAL GUIDE LINES

5.5.1.0 PUMP

5.5.1.1 NO / Insufficient flow

a) Low oil level in the Bearing sump/Reservoir.

b) Insufficient oil supply to the suction port/ suction strainer clogged.
c) Internal leakage in the pump.
d) wear out of component due to dirt.
e) Wrong direction of rotation.
f) Improper assembly.
g) Fluctuation in supply voltage.

5.5.1.2 Excessive Noise

a) Excessive drive speed.

b) Wrong direction of rotation
c) Faulty sealing.
d) Air entering in suction.
e) Damaged bearings.
f) Improper assembly units.
g) Improper mounting of pump station.

5.5.1.3 No/ Insufficient System pressure

a) Internal leakage due to worn out parts.

b) Improper seating of valves.
c) Leakage in the supply line
5.5.2.0 RELIEF VALVE AT THE PUMP

5.5.2.1 No/Insufficient flow

a) Setting of the relief valve low.

b) Valve seat is damaged.
c) Improper seating of valve seat.

5.5.2.2 No/Insufficient pressure

a) Valve setting low.

b) Damaged valve seat.
c) Improper seating of valve seat.

5.5.2.3 Excessive noise

a) Faulty pressure setting.

b) Air lock.
c) High viscosity of the oil.
d) Excessive line pressure.

5.5.3.0 PRESSURE GAUGE

5.5.3.1 No/ Improper reading

a) Defective pressure gauge.

b) Air lock in the system.
c) Faulty gauge isolation valve.

5.5.4.0 FILTER

5.2.4.1 Excessive noise / vibration

a) Low filtering capacity.

b) Faulty attachment.
c) filter clogged.
5.5.5.0 GENERAL CHART OF SYMPTOMS OF CAUSES AND REMEDIES OF TROUBLE IN
OIL HYDRAULICS SYSTEM
Symptoms Causes Remedies in Field
Noisy pump Cavitation Use oil of low viscosity.

Vary the suction head of the

pump.

Restricted suction Clean inlet screen/ filter.

Air leak at the intake of the Pour oil over joints, spot
pipe connection joints with pumps running
and tighten.

Air leak at the pump shaft Lubricate or renew packing

accurately align pump motor
shaft.

Air drawn into the system Raise the oil level in the
from oil sump sump, Discharge below oil
level.

Worn valves, vanes, piston Renew worn parts.

rings, gears etc.

Sticking valves or vanes Check for impurities or

metal particles in oil.

Excessive heating of Internal leakage Renew worn parts such as

pump gears, vanes, piston rings,
valves etc.

Internal leakage caused by Use heavier bodied oil.

thin oil
Check pressure relief valve
setting.
Check pressure relief valve
for leak.
Check for pipe line
obstructions.
Excessive heating of
pump Insufficient clearance of Check assembly of pumps
moving parts

Heavy bodied oil causing Use of oil of higher viscosity.

excessive fluid friction in the
system

Diminished or Pumps parts worn out or oil Check consistency of oil.

Insufficient delivery thickened by impurities
of pump

Diminished pump Short circuit in pump Check seal between inlet

delivery pressure and outlet ports of the
pump
Erratic and sluggish Oil viscosity is too high. Use oil of lower viscosity or
operation Insufficient power. oil as specified by the
manufacturer.

Unsteady pump Air entering the system Release air from the system.
pressure
Check pressure relief valve.

Inspect suction line for

obstruction and check
efficiency of the pump.

Check valve troubles Valve seating Check condition of the valve

seat.

If worn or ball is in poor

condition, reset new ball by
tapping against seat with
soft brass rod.
Needle valves Needle worn regrind end and relap.

Loosened parts / improper Check whether cover binds

seating plunger when tightened &
re.

Improper pressure
adjustment caused by
broken spring.

Valve inserted wrong.

Leaky gasket.

5.5.6.0 WHAT DIRT DOES TO HYDRAULIC COMPONENTS.

Hydraulic component manufactures agree that dirt is responsible for a majority of

malfunctions and unsatisfactory performance of the components.
Here’s what dirt does to components :
Check valves

Causes wear on ball and seats creating leakage. Dirt in valves permits fluid to bypass
check.

Pumps

Erodes wear parts. Causes sticking of vanes creating erratic action. Causes the valves
to wear out the cam ring. Wears out rotor slots increases shaft journal and bearing
wear increases gear wear with resultant inefficiency. Dirt in compansator controls on
variable volume pumps causes sticking, slow response and erratic delivery thus
affecting the performance of the entire system, creating excessive heat and
insufficient use of horse- power.
Relief valves

Causes chatter. Accumulated dirt causes relief valves to fail safe and pressure
becomes erratic which affects function of the entire system.

Fluids

acts as a catalyst and breaks down molecular structure causing gummy residual
varnish. Dirt in the tank attracts additives and changes composition of the fluid.

System

Hydraulic system malfunctions due dirt can result in serious damage to equipment,
safety hazards, scraping of parts due to poor finishes, insufficient pressure as well as
higher hydraulic fluid costs with resulting increase in disposal problems.
 SECTION 6.0
6.1 List of Maintenance Spares
6.1 List of Maintenance Spares
SL.No. DESCRIPTION PART NO. QTY
1 CHECK VALVE H28-100205-9 2
2 CHECK VALVE H28-110012-2 2
3 DIFFERENTIAL PR.INDICATOR CUM SWITCH H56-320002-1 2
4 PR.GAUGE, 0-25 BAR, 100mm dial, Glycerine filled H22-341904-7 4
5 PR.GUAGE 0-600 BAR,100mm dial, Glycerine filled H22-341704-7 2
6 PR.GUAGE 0-16 BAR,100mm dial, Glycerine filled H22-141107-7 2
7 FILLER CUM BREATHER H23-154680-1 2
8 SUCTION STRAINER H23-393150-1 2
9 FILTER ELEMENT FOR FILTER 1002012-4000 2
10 NEEDLE VALVE, CS, 1/2" BSP, H28-400002-1 1
11 PRESSURE RELEIF VALVE H48-521566-2 2
12 PRESSURE RELEIF VALVE H48-512211-5 1
12 PRESSURE RELEIF VALVE H48-511262-5 1
13 PRESSURE TRANSMITTER E99-910019-G 1
14 PRESSURE SWITCH H50-120429-2 2
15 GEAR PUMP H51-115818-6 2
16 RADIAL PISTON PUMP H51-411709-9 1
17 LEVEL GAUGE H99-000185-9 2
18 TEMP.GAUGE,100MM,0-100 DEG C,1/2"-225,REAR CONN H54-425124-7 2
19 FLOW SWITCH H55-110406-6 2
20 FLOW SWITCH H55-110906-6 1
21 FLOW SWITCH H55-110506-6 1
 SECTION 7.0

Catelogues
CATALOGUES ATTACHED

1) ELECTRIC MOTOR
2) GEAR PUMP
3) RADIAL PUMP
4) HEAT EXCHANGER
5) DUPLEX FILTER
6) DIFFERENTIAL PR. SWITCH
7) PRESSURE TRANSMITTER
8) PRESSURE SWITCH
9) FLOW SWITCHES
SECTION 8.0

Drawings